Integrated fiber cement and foam as insulated cladding with enhancements

ABSTRACT

An integrated fiber cement and foam cladding system is provided that incorporates foam or similar light weight material to improve the insulation capacity of the cladding system. The system includes at least a fiber cement layer and a foam layer disposed on the backside of the fiber cement layer. The system improves the R-value of the building, a measure of the building&#39;s resistance to transferring heat or thermal energy.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. §119(e)of U.S. Provisional Application No. 61/619,872, filed on Apr. 3, 2012,the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure generally relates to building constructionmaterials and methods, and more particularly relates to composite fibercement cladding with improved properties and methods of installing suchmaterial.

2. Description of the Related Art

The future of building construction is moving towards providing aninsulated, energy efficient building envelope. In particular, there isan increasing demand for energy efficient residential and commercialconstructions which require walls having greater building insulationratings. The R-value of building insulation is a measure of itsresistance to transferring heat or thermal energy. Greater R-valuesindicate more effective building insulation. The higher the R-value ofthe insulation of a building, the easier it is to maintain a temperaturedifferential between the interior and the exterior of the building overan extended period of time. One approach to improving the energyefficiency of a building structure is to add insulation to the exteriorwalls. Adding additional wall insulation, however, can drive up the costof construction as it requires additional material and installationlabor. Adding additional exterior wall insulation can adversely affectthe aesthetics, water management, and other properties of the wallstructure assembly, as well as impact the design of other components ofthe wall.

Foamed material is one type of material that can be used to insulatebuilding structures. While foamed material has been used as aninsulation material in certain building construction, it has not beenused as efficiently and effectively as it could be. For example, foamsheathing or backing boards have been placed between the framing andfiber cement exterior sidings of a building structure to provideadditional insulation. The foam sheathing or backing boards aretypically tacked or fastened to the framing prior to installation of theexterior cladding. To reduce the amount of air exchanged between theinside and the outside of the building structure, the seams of the foamsheathing or backing boards often need to be sealed or taped. As such,the installation of the foam sheathing requires additional processingsteps. The foam installation may also create aesthetic issues with theexterior siding, such as causing a wavy appearance as when siding isinstalled over deformations in the foam where fasteners compress theunderlying foam.

Additionally, in high-wind regions, sidings are frequently blown offwalls of building structures. To improve wind resistance, shims areoften used to create a uniform and flat surface for attachment of thesidings so as to reduce gaps that could catch the wind. Face nailinginstead of blind nailing is also recommended, particularly for fibercement sidings in regions with high wind speed. However, these existingmethods for enhancing wind resistance of sidings require additionalmaterial and labor, and can detract from the aesthetics of exteriorbuilding structure.

In view of the foregoing, there is a need for a different buildingconstruction material and technique for improving the insulation ofbuilding structures and improving the wind resistance of exteriorsidings. There is also a need for an improved fiber cement compositeinsulation building material designed without the shortcomings ofexisting site assembled systems that incorporate foam as an insulatingmaterial.

SUMMARY OF THE INVENTION

Accordingly, disclosed herein are integrated fiber cement and foamcladding systems that incorporate foam or similar light weight material,such as lightweight mats of fiberglass or Rockwool, for improving theinsulation capacity of a cladding material. In various embodiments, theintegrated fiber cement and foam cladding system is designed to improveexisting uses of foam and fiber cement during the construction of a wallor other structure in one or more of the following areas: reducedinstallation time, increase wind loads, simplified assembly, nailholding ability, resistance to thermal bridging, water management, andtransportation. As used herein, the terms “foam” or “foamed material”are broad terms and shall have their ordinary meaning and shall include,but not be limited to polymeric foams, inorganic foams, cementitiousfoams, glass foams, ceramic foams, metallic foams, aerogels, syntacticfoams and the like in a substantially solid state.

In one application, the integrated fiber cement and foam system of thepresent disclosure is prefabricated and designed with a structure thathas sufficient integrity to sustain its connection with the buildingframe under high wind loads.

Accordingly, in one embodiment of the invention, there is provided aprefabricated integrated fiber cement and foam insulation panelcomprising: a fiber cement layer having a front side and a back sidespaced apart to define an intermediate portion and an edge memberextending around the intermediate portion; a foam layer having a frontside and a back side spaced apart to define an intermediate portion andan edge member extending around the intermediate portion; and anadhesive layer disposed between the fiber cement layer and the foamlayer, said adhesive layer adapted to attach the fiber cement layer tothe foam layer.

In a further embodiment of the invention, the foam layer is configuredto facilitate alignment and assembly of multiple panels together. In oneimplementation, the foam layer is profiled with an interlocking featuresuch that adjacent foam layers will interlock when the siding panels areinstalled. This interlocking feature facilitates alignment of the sidingpanels, inhibits the infiltration of air and water between the panelsand also increases wind loads on the structure by improving theresistance of the panels to the effects of strong winds impinging on thewall.

Accordingly, in a further embodiment of the invention, there is providedan exterior cladding system for building structures. The systemcomprises a first panel and a second panel, wherein each panel comprisesa fiber cement layer and a foam layer, the fiber cement layer of eachpanel being secured to the respective foam layer, the foam layer of eachpanel comprises interlocking means. In one embodiment of the inventionthe interlocking means comprises a receiving channel or mating channelwhereby the receiving channel or mating channel of the foam layer of thefirst panel engages with the receiving channel or mating channel of thefoam layer of the second panel when the first and second panel areplaced in a contiguous arrangement such that at least a portion of thereceiving or mating channel of each of the foam layers abut in aninterlocking arrangement.

In a further embodiment of the invention the fibre cement layer issecured to the foam layer by means of an adhesive layer. It is to beunderstood that any other suitable type of securing means known to aperson skilled in the art could also be used. Preferably the method ofsecuring the fibre cement layer to the foam layer allows for thermalcyclic differential expansion between the fibre cement layer and thefoam layer and or any other layers which may be present.

Accordingly, in a further embodiment of the invention, there is providedan exterior cladding system for building structures. The systemcomprises a first panel and a second panel, wherein each panel comprisesa fiber cement layer and a foam layer, wherein the fiber cement layer ofeach panel is pre-attached to the respective foam layer by an adhesiveselected to accommodate the stresses generated by cyclic differentialexpansion between the fiber cement layer and the foam layer, wherein thefoam layer of the first panel comprises an elongate mating channeldefined by two opposing sidewalls formed along a longitudinal edge ofthe foam layer of the first panel, wherein the foam layer of the secondpanel comprises an elongate protrusion formed along a longitudinal edgeof the foam layer of the second panel, the protrusion on the foam layerof the second panel being configured to be received into the matingchannel on the foam layer of the first panel in a manner such that thesidewalls formed on the foam layer of the first panel enclose theprotrusion formed on the foam layer of the second panel in a manner suchthat the foam layer of the first and second panels interlock.

In a further embodiment of the invention, the fiber cement layer isconfigured to facilitate alignment and assembly of multiple panelstogether. In one implementation, the fiber cement layer is profiled withan interlocking feature such that adjacent fiber cement layers willinterlock when the siding panels are installed. It is to be understoodthat in other embodiments of the invention the foam layer of theexterior cladding system can be configured such that the interlockingmeans is located on any two opposing edges of the foam layer. In analternative embodiment of the invention the interlocking means can belocated on at least two opposing edges of the foam layer.

Conveniently in a further embodiment of the invention, the foam layercomprises an interlocking feature extending around at least a portion ofthe edge member to facilitate alignment and assembly of the multiplepanels together. In a further embodiment of the invention, theinterlocking feature is configured to improve the wind load of theinstalled prefabricated integrated fiber cement and foam insulationpanel. In one embodiment of the invention, the interlocking featurecomprises complementary shaped tongue or groove configurations. In afurther embodiment of the invention, the foam layer is configured tointerlock with adjacent foam layers in a manner such that the integratedfiber cement and foam insulation panels are arranged in a nestedconfiguration.

In yet another application, the integrated fiber cement and foam systemprovides foam backed siding planks that provide the functionalequivalent of continuous insulation and a thermal break across theframing members. In yet another embodiment, the integrated fiber cementand foam system is configured to form a substantial air seal between theindividual components of the system. In yet another arrangement, theintegrated fiber cement and foam system provides a foamed back lap orpanel siding that allows the installer the flexibility to adjust thejoints between individual laps or panels and yet maintain a sealed airbarrier. In yet another application, the integrated fiber cement andfoam system is designed to aid in the placement of fasteners.

In yet another arrangement, the integrated fiber cement and foam systemis designed with a continuous, uninterrupted drainage plane and canprevent water from being trapped between the foam layer and wallsheathing which normally surrounds the structural support of thebuilding structure. In one embodiment of the invention, either the foamlayer or the fiber cement layer is configured with one or more drainagechannels to provide a drainage plane. In other implementations, drainagechannels are formed either on the interior or exterior surface of thefoam layer or within the foam layer itself for effective watermanagement within the wall cavities. In a further embodiment of theinvention, a plurality of drainage channels are formed in the foam layerof the integrated fiber cement and foam insulation panel. In a furtherembodiment of the invention, a plurality of drainage channels are formedon at least one of the surfaces of the foam layer of the integratedfiber cement and foam insulation panel. In a further embodiment of theinvention, a plurality of drainage channels are formed inside the foamlayer of the integrated fiber cement and foam insulation panel. In afurther embodiment of the invention, a plurality of drainage channelsare formed on at least one of the surfaces of the fiber cement layer ofthe integrated fiber cement and foam insulation panel. In a furtherembodiment of the invention, a plurality of drainage channels are formedinside the fiber cement layer of the integrated fiber cement and foaminsulation panel. In a further embodiment of the invention theintegrated fiber cement and foam insulation panel, at least one surfaceof the foam layer is provided with a pattern which provides a series ofdrainage channels in the integrated fiber cement and foam insulationpanel. The pattern can adopt any suitable form, for example, a Chevronpattern or a plurality of repeating emblems or logos. In a furtherembodiment of the invention the foam layer is porous. Conveniently, thefoam layer is sufficiently porous to permit water drainage.

In a further embodiment of the invention, the integrated fiber cementand foam insulation panel comprises a fiber cement layer and a foamlayer, wherein the width of the foam layer is smaller than the width ofthe fiber cement panel so as to form an overhang on the integrated fibercement and foam insulation panel.

In a further embodiment of the invention, the integrated fiber cementand foam insulation panel further comprises a reinforcement mesh layer.In one embodiment of the invention, the integrated fiber cement and foaminsulation panel further comprises a reinforcement mesh layer embeddedin said foam layer. In a further embodiment of the invention, theintegrated fiber cement layer and foam insulation panel furthercomprises a reinforcement mesh layer intermediate the fiber cement layerand the foam insulation layer. In a further embodiment of the invention,the integrated fiber cement layer and foam insulation panel furthercomprises a reinforcement mesh layer embedded in the fiber cement layer,intermediate the fibre cement layer and the foam insulation layer. In afurther embodiment of the invention, the integrated fiber cement andfoam insulation panel further comprises one or more fastening tabs. In afurther embodiment, the one or more fastening tabs are disposed betweenthe foam layer and the fiber cement layer. In another embodiment, theone or more fastening tabs are disposed on and/or adjacent to the backside of the foam layer. In a further embodiment, the one or morefastening tabs are attached to the panel in a manner such that a portionof each tab extends outwardly from the lateral edges of the foam layer.

In an embodiment, a method of installing integrated fiber cement andfoam insulation panels on a building structure having a framingcomprises the steps of: installing one or more starter strips at thebase of a wall of the building to form a plank angle; and installing thefiber cement and foam insulation panels sequentially up the wall. In anembodiment, the method further comprises the steps of crotchedlyvertically nesting the fiber cement and foam insulation panels. In anembodiment, the method further comprises the steps of installing aninsert behind a butt joint intersection between adjacent fiber cementand foam insulation panels; wherein the insert comprises a foam layerwith the same profile as a foam layer in the fiber cement and foaminsulation panels as a flashing layer. In a further embodiment, whereinthe fiber cement and foam insulation panel comprises one or morefastening tabs, the method further comprises the steps of installing thepanels to the framing by attaching the one or more fastening tabs to theframing, wherein the fastening tabs are attached to the fiber cement andfoam insulation panels in such a manner that at least a portion of eachfastening tab is concealed from view when the panels are installed onthe building structure.

In yet another application, the integrated fiber cement and foam systemis configured to be stacked in a manner during transit so as to reducedamage normally sustained by foam materials while in transit.

In some embodiments, the integrated fiber cement and foam insulationsystem comprises a prefabricated fiber cement and foam insulation sidingpanel. The prefabricated panel includes a fiber cement layer and a foamlayer attached thereto, preferably by an adhesive. The fiber cementlayer can be a panel, a plank, a shingle, a strip, a trim board, or thelike. In a further embodiment of the invention the fiber cement and foaminsulation siding panel comprises an oriented strand board (OSB), saidOSB is attached to the foam layer on the opposing side of the fibercement layer. Various embodiments of the integrated fiber cement andfoam insulation system will be described in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate an integrated fiber cement foam and insulationsiding panel according to one embodiment of the present disclosure.

FIGS. 2A-2C illustrate an integrated fiber cement foam and insulationsiding panel according to another embodiment of the present disclosure.

FIGS. 3A-3I illustrate embodiments of foam layer profiles that can beincorporated in an integrated fiber cement and foam insulation panel.

FIGS. 3J-3N illustrate profiles of foam starter strips of variousembodiments.

FIG. 4A-4D illustrates an embodiment of integrated fiber cement and foaminsulation panels incorporating drainage features of variousembodiments.

FIG. 5 illustrates an integrated wall assembly according one embodimentof the present disclosure.

FIG. 6A-6I illustrate various embodiments of an integrated fiber cementand foam insulation panel with integrated fastening tabs.

FIG. 7 illustrates yet another embodiment of the present disclosureshowing a prefabricated integrated fiber cement and foam insulationpanel with a backing disposed on the backside of the foam layer.

FIG. 8 illustrates yet another embodiment of the present disclosureshowing an integrated fiber cement and foam insulation system thatincorporates a discontinuous layer in the foam backing for acousticdampening purposes.

FIG. 9 illustrates an embodiment of the present disclosure showing afiber cement and foam insulation panel designed for high shearapplications.

FIGS. 10A-10C illustrate embodiments showing two fiber cement and foaminsulation panels joined together with a butt joint.

FIGS. 11A and 11B illustrate certain connection mechanisms that can beused to join adjacent integrated fiber cement and foam panels at a buttjoint.

FIG. 12 depicts a flow diagram of installation of fiber cement and foaminsulation plants according to one embodiment.

FIG. 13 depicts yet another embodiment of an integrated fiber cement andfoam insulation panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

References will now be made to the drawings wherein like numerals referto like parts throughout. FIG. 1A illustrates an integrated fiber cementand foam insulation panel 100 configured for exterior sidingapplications in accordance with various embodiments of the presentdisclosure. The panel 100 generally includes a fiber cement layer 102and a profiled foam layer 104 attached thereto. The fiber cement layer102 can be in the form of a plank, a siding, a shingle, a strip, a trimboard, or various other building components. In a preferred embodiment,the fiber cement layer 102 is configured as a siding used for exteriorwall applications. The profiled foam layer 104 can be made ofopen-celled and/or closed-celled foam or other similar lightweightmaterial with insulating material properties, such as polystyrene foam,mineral based foams, foamed cement or gypsum, phenolic foams, andaerogels. Additionally or alternatively, the profiled foam layer 104 mayalso comprise mineral fibers or fiberglass, cellulose, polyisocyanurate,polystyrene, polyurethane, cotton fibers, and mineral wool. The profiledfoam layer 104 may also include as part of its formulation waterrepellent agents, fire retarding agents, termiticides, insecticides orrepellents, gases that enhance R-value retention, fillers that enhanceR-value and the like. In some embodiments, the profiled foam layer 104may be a composite foam comprised of materials with differentialcomposition, density, compressive strength or fastener holding ability.As shown in FIG. 1A, the profiled foam layer 104 is adhered to aninterior surface or backside 105 of the fiber cement layer 102 andextend substantially across the length of the fiber cement layer 102such that the profiled foam layer can provide continuous insulation andthermal break across between the fiber cement layer and framing membersupon installation of the panel 100. Preferably, the profiled foam layer104 extends partially across the width of the fiber cement layer 102 soas to leave an overhang portion 108. The overhang portion 108 is adaptedto overlap with adjacent panels when the panels are installed in anesting configuration. In other embodiments, the profiled foam layer 104does not extend across the entire length of the fiber cement layer 102so as to accommodate possible expansion of the foam due to thermaleffects upon installation of the panel 100.

In various embodiments, a specially formulated adhesive layer 106 isuniformly disposed between the interior surface 105 of the fiber cementlayer 102 and the profiled foam layer 104 to form a strong and uniformbond between the foam and the fiber cement across the entire panel 100.The adhesive layer 106 is preferably formulated to establish aneffective chemical and/or mechanical interlocking bond with both thefoam and the fiber cement. In one embodiment, the adhesive layer 106 maybe made of polyurethane, poly urea or isocyanate based materials.Preferably, the adhesive layer when bonding styrene foam to fiber cementis a high-shear strength adhesive that will not attack or eat away ateither the fiber cement or styrene foam. Preferably, the adhesive layerwill offer a durable bond between the fiber cement and foam layers in avariety of environmental condition including cold and warm conditions,dry and wet conditions, and freeze-thaw conditions, with salt, and inalkaline solutions, etc. The adhesive layer also preferably maintainsits adhesive properties through exposure to many cycles of temperatureswings (hot to cold), moisture conditions (wet to dry), and/orfreeze-thaw cycles.

In one embodiment, the adhesive layer can be made of a water basedadhesive, solvent based adhesive, and 100% solid. The adhesive layer canbe formed in a liquid form, in a paste form, and/or in a solid form ashot melt adhesive. The chemistries can include one and two componentpolyurethane, one and two part epoxy, polyvinyl acetate, polyolefin,amorphous polyolefin, pressure sensitive polyolefin, poly ethylene vinylacetate, and/or polyamide. In some embodiments, the adhesive may be ahot melt or reactive hot melt adhesive. In such embodiments, it ispreferable that the hot melt adhesive establishes a very quick bond sothat the fiber cement product bonded with foam can be moved and stackedin production.

In a preferred embodiment, the adhesive layer 106 is selected toaccommodate the possible stresses generated by cyclic differentialexpansion between the foam and the fiber cement portions of theintegrated fiber cement and foam insulation panel. In variousembodiments, the adhesive can be applied onto the fiber cement layer byspraying, roll coating, etc. The adhesive layer 106 may bediscontinuous, such as with partial coverage over the portion of theback surface 105 of the fiber cement layer 102 which mates to theprofiled foam layer 104 to lead to a material and cost savings. Adiscontinuous adhesive layer 106 may also facilitate the evaporation ofmoisture from the interface between the elongate fiber cement layer 102and the profiled foam layer 104. In other embodiments, the adhesivelayer 106 may be continuous, such as with full coverage over the portionof the back surface 105 of the fiber cement layer 102 which mates to theprofiled foam layer 104.

In another embodiment, the profiled foam layer 104 may be joined to thefiber cement layer 102 by laminating the profiled foam layer 104 to theinterior surface or back face 105 of the fiber cement layer 102.Lamination may be achieved by mechanical means, by use of adhesives orby forming the foam layer directly on the fiber cement layer eitherbefore or after curing of the fiber cement layer by autoclaving,depending on the materials used. In yet another embodiment, the profiledfoam layer 104 can be formed by applying a layer of foam generatingliquid to the interior surface or back face 105 of the fiber cementlayer 102 and allowing the layer of foam generating liquid to expandsuch that the entire interior surface or back face 105 of the fibercement layer 102 is substantially covered with foam. In this embodiment,the profiled foam layer 104 may be formed into a predetermined shape andprofile after foam generation by use of routing, molding or machiningequipment as is known to those skilled in the art. Alternatively, theprofiled foam layer 104 may be formed by allowing the layer of foamgenerating material to expand into a mold or container of apredetermined shape or profile, followed by an operation that releasesthe foam layer from the mold or container.

With further reference to FIG. 1A, in various preferred embodiments, theprofiled foam layer 104 can include drainage channels 112 extendingthrough the exterior or interior of the foam to provide water drainage.The profiled foam layer 104 can also include profiled opposinglongitudinal edges 110, 111. The profiled edges 110, 111 are configuredto interlock with corresponding profiled edges on adjacent profiled foamlayers to facilitate alignment of the panels 100 during installation. Incertain implementations, the interlocking features formed by the edges110, 111 of the profiled foam layer 104 are adapted to allow the panels100 to nest with each other as they are assembled on a wall.

As described in greater detail below, in some embodiments, theinterlocking features are specially configured to interlock in a mannerthat improves the wind load of the panels. As shown in FIG. 1A, one ofthe edges 111 of the profiled foam layer 104 is configured with achannel 115 defined by two parallel sidewalls 114 a, 114 b extendinglongitudinally across the edge 111. The parallel sidewalls 114 a, 114 bin conjunction with the channel 115 formed in the profiled foam layer104 interlock and secure the edge 110 of adjacent foam layers so as toimprove wind resistance of the panel 100. The interlocking features canalso be adapted to provide an air seal, whether with or without use ofsealants such as caulk or tape. In some embodiments, the interlockingfeature can also be adapted to meet the requirements for continuousinsulation and thermal break across the framing members. In someimplementations, the interlocking features are also adapted to providethe installer a means to adjust joint spacing so as to efficiently spacepanels along the wall to reduce material use and installation labor.

FIG. 1B illustrates a manner in which a plurality of integrated fibercement and foam insulation panels 100 a, 100 b can be arranged asassembled on a building frame to form an exterior cladding, such as forexterior siding applications. In various preferred embodiments, thepanels 100 a, 100 b are prefabricated so that the installer can simplyremove the packaging from each panel and attach the panels to the frameof a building. As shown in FIG. 1B, the panels 100 a, 100 b arepositioned in a nesting configuration whereby the profiled edges 110 a,111 a, 110 b, 111 b of the foam layers 104 a, 104 b interlock the panelsso as to provide an air seal without sealer and to facilitate alignmentand installation. The panels can be positioned such that theinterlocking foam layers can provide continuous insulation and thermalbreak across the building framing members. As also shown in FIG. 1B, thedrainage channels 112 allow water to drain from the interior of thepanels 100 a, 100 b. The drainage channels 112 can be formed either onthe interior or exterior surface of the foam layer or within the foamlayer itself for effective water management within the wall cavities. Inone implementation, the profiled foam layer 104 has a thickness of about¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cement layer 102has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175 cm).In one embodiment, the profiled foam layer 104 can have a density ofbetween 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and an R value ofbetween R3 and R7, preferably R3, such as R3, R5, and R7.

With further reference to FIG. 1B, in overlapping siding applications,the parallel side walls 114 a, 114 b on the lower edge 117 a of theprofiled foam layer 104 a directly contact and enclose both sidesurfaces of the upper edge 119 b of the adjacent profiled foam layer 104b, thus mechanically connecting the profiled foam layers 104 a, 104 bwith each other, which in turn improve the wind load of the panels 100a, 100 b. In one embodiment, both the upper and lower edges 117 a, 117b, 119 a, 119 b of the profiled foam layers 104 a, 104 b have a slopedprofile such that the parallel side walls 114 a, 114 b are not evenlydisposed. Preferably, the sidewall 114 b in contact with the fibercement layer 102 a, 102 b is positioned higher than the sidewall 114 a,114 b not in direct contact with the fiber cement layer.

FIG. 2A illustrates an integrated fiber cement foam and insulation panel200 according to another embodiment of the present disclosure adaptedfor exterior siding applications in which the sidings are not in anesting configuration. As shown in FIG. 2A, the panel 200 includes afiber cement layer 202 and a profiled foam layer 204 attached thereto.The profiled foam layer 204 can be attached to the fiber cement layer202 by an adhesive layer 206 or can be integrally formed on the fibercement layer 202. In this embodiment, the longitudinal edge 209 of theprofiled foam layer 204 is substantially flush with the longitudinaledges 207 of the fiber cement layer 202. As also shown in FIG. 2A, thefoam layer 204 has interlocking features 210, 211 adapted for aligningand coupling adjacent panels 200 during assembly, such as a tongue andgroove joint. Additionally, drainage channels 212 can be formed in thefoam layer 204 as shown in FIG. 2A. In certain preferredimplementations, the thickness of the foam and fiber cement layers canbe selected to provide target insulation R values and also allow thepanels to be integrated into the building structure without requiringalterations of the wall or framing dimensions of existing buildingstructures. In one implementation, the foam backing 204 has a thicknessof about ¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cementlayer has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175cm). In one embodiment, the foam backing 204 can have a density ofbetween 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and can have an Rvalue of between R3 and R7, preferably R3, such as R3, R5, and R7. Inone embodiment, siding nails from 6 d to 16 d can be used, such as 6 d,10 d, and 16 d.

FIG. 2B illustrates one embodiment in which integrated fiber cement andfoam insulation panels 200 can be arranged when they are assembled on abuilding frame to form an exterior cladding. As shown in FIG. 2B, thefoam layers 204 a, 204 b can include interlocking features 210′, 211′such as a tongue and groove, such that the fiber cement layers 202 a,202 b form a substantially planar exterior surface. In some embodiments,the interlocking features in the foam layers may be formed using thesame techniques as for forming drainage channels in a separate step. Inaddition, in the case of EPS foams, the polystyrene beads may be placedin a mold specifically designed to yield a foam panel having bothdrainage channels and interlocking features.

FIG. 2C shows an alternative embodiment in which the integrated fibercement and foam insulation panels can be arranged when they areassembled on a building frame to form an exterior cladding. As shown inFIG. 2C, the fiber cement layers 202 a, 202 b can include interlockingfeatures 210″, 211″ such that the fiber cement layers 202 a, 202 b forma substantially planar exterior surface. In the illustrated embodimentin FIG. 2C, the profiled foam layers 204 a, 204 b are configured withoutinterlocking features. It should be appreciated that in variousembodiments, either the profiled foam layers 204 a, 204 b and/or thefiber cement layers 202 a, 202 b can have interlocking features 210,211.

In various embodiments, the fiber cement and foam insulation systemsdisclosed herein are designed with innovative water managementmechanisms and improved ventilation functions to facilitate ventilationand drainage of water and other liquids from the wall cavity. As shownin FIG. 1A, the foam layer 104 may incorporate various drainage channels112. The drainage channels are designed to divert water away from thepanels so as to prevent water from entering the home, prevent damage tothe panels, and prevent the panels from attracting insects.

FIGS. 3A-3I are schematic illustrations of certain embodiments of theprofiled foam layer 104 that is part of the integrated fiber cement foamand insulation panel 100. In some embodiments, the profiled foam layer104 has a first face 131 that is configured to be in direct contact witha fiber cement panel and an opposing face 133 that is set at an anglerelative to the first face 131 so as to form an inclined surfacerelative to the fiber cement layer. The inclined surface facilitatesmounting of the panels in a nesting configuration. In some otherembodiments, the profiled foam layer 104 can be configured to allowstacking of the integrated fiber cement and foam panels during transitso as to reduce damage otherwise normally sustained by foam materialswhile in transit. As illustrated in FIGS. 3A-3D, the profiled foam layer104 can include complementary angled edges to facilitate nesting. In oneembodiment, an angle 134 measuring about 45 degrees relative to thevertical axis can be formed on the upper edge and a complementary angle136 measuring about 135 degrees relative to the vertical axis can beformed on the lower edge. In some embodiments, the vertical axis can bethe vertical axis of the integrated fiber cement and foam panel when theintegrated fiber cement and foam panel is positioned or assembled on abuilding structure. In some other embodiments, the angles 134, 136 canbe 0 to 90 degrees, 90 degrees to 180 degrees, 0 to 45 degrees, 45degrees to 90 degrees, 90 degrees to 135 degrees.

In the embodiment shown in FIG. 3B, side 138 can have a range between3.5 inches (8.9 cm) to 11 inches (27.9 cm), side 139 can have a rangebetween 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 140 can have arange between 0.0625 inch to 0.375 inch (0.159 cm to 0.95 cm), side 141can have a range between 0.25 inch to 1.25 inches (0.625 cm to 3.175cm), side 142 can have a range between 0.0625 inch to 0.375 inch (0.159cm to 0.95 cm), side 143 can have a range between 0.0625 inch to 0.375inch (0.159 cm to 0.375 cm), and side 144 can have a range between 0.75inch to 1.75 inch (1.91 cm to 4.45 cm). Angle 145 can have a rangebetween 30 degrees to 60 degrees, angle 146 can have a range between 30degrees to 60 degrees, and angle 147 can have a range between 1.5degrees to 5.0 degrees.

In the embodiment shown in FIG. 3C, side 148 can have a range between3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 149 can have a rangebetween 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 150 can have arange between 0.0625 inches to 0.375 inches (0.159 cm to 0.95 cm), side151 can have a range between 0.625 inches to 1.75 inches (1.59 cm to4.45 cm), and side 152 can have a range between 0.25 inches to 1.25inches (0.625 cm to 3.175 cm). Angle 153 can have a range between 30° to60°, angle 154 can have a range between 30° to 60°, and angle 155 canhave a range between 1.5° to 5.0°.

In the embodiment shown in FIG. 3D, side 156 can have a range between3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 167 can have a rangebetween 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 158 can have arange between 0.25 inches to 1.25 inches (0.635 cm to 3.175 cm), andside 159 can have a range between 0.625 inches and 1.75 inches (1.59 cmto 4.45 cm). Angle 160 can have a range between 30° to 60°, angle 161can have a range between 30° to 60°, and angle 162 can have a rangebetween 1.5° to 5.0°.

FIGS. 3E-3I depict additional profiles of foam layers that can be partof the integrated fiber cement foam and insulation panel.

FIGS. 3J-3N depict profiles of foam starter strips that can be placed atthe bottom of a wall to start the proper kick out angle for installationof siding going up a wall.

In the embodiment shown in FIG. 3J, side 163 can have a range between1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 164 can have a rangebetween 0.0625 inches to 1.0 inches (0.16 cm to 2.54 cm), and side 165can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm).Angle 166 can have a range between 30° to 60° and angle 167 can have arange between 1.5° to 5.0°.

In the embodiment shown in FIG. 3K, side 168 can have a range between1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 169 can have a rangebetween 0.0625 inches to 1.0 inches, (0.159 cm to 2.54 cm) and side 170can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm).Angle 171 can have a range between 30° to 60° and angle 172 can have arange between 1.5° to 5.0°.

In the embodiment shown in FIG. 3L, side 173 can have a range between1.0 inches to 1.5 inches (0.159 cm to 2.54 cm), side 174 can have arange between 0.0625 inches to 1.0 inches (0.159 cm to 2.54 cm), andside 175 can have a range between 0.5 inches to 1.5 inches (1.27 cm to3.81 cm). Angle 176 can have a range between 30° to 60° and angle 177can have a range between 1.5° to 5.0°.

In various embodiments, the fiber cement and foam insulation panelsdisclosed herein are designed with innovative water managementmechanisms to facilitate ventilation and drainage of water and otherliquids from the wall cavity. With reference to FIGS. 4A-4D, in variousembodiments, the drainage channels may take on a variety of patternsincluding grooves, designs or logos 113. As depicted in the illustratedembodiments, the drainage channel patterns are formed on the back sideof the foam layer 104. However, it should be appreciated that in variousembodiments, the drainage channels 112 and grooves, designs or logos 113may be formed along any surface of the foam, or in other embodiments,through the thickness of the foam. The drainage channels, can be made bymachining or hot wire cutting or a spindle molder with aluminum blades.The channels or features may also be formed using molding techniquessuch as injection molding. In alternative embodiments, the drainagechannels 112 can take the form of an embossed or debossed feature in theform such as an image, symbol, design or logo. In another embodiment,the drainage channels can take the form of chevrons or tread designs. Insome embodiments wherein thermoplastic foams, such as polystyrene foams,are used, the drainage channels 112 may be added by machining using arouter or grinder or by using a hot wire, water jet cutting or lasercutting means. In the case of thermosetting foams, water channelrouting, grinding, or injection molding techniques may be preferred. Inyet other embodiments, such as foams made out of expanded polystyrene(EPS), the drainage channels may be incorporated into the mold used toform the foam. In other embodiments, such as foams made out of cut blockEPS foam, the porosity of the foam can function as the drainage channelsor to improve ventilation. In such embodiments, the foam porosity can beadjusted to allow drainage. As such, the foam according to someembodiments of the present disclosure may not require drainage channels.

FIG. 5 illustrates an integrated wall assembly 300 according to oneembodiment of the present disclosure. The wall assembly 300 can includea sheathing 301, such as oriented strand board (OSB), and a plurality ofprefabricated fiber cement and foam insulation panels 300 a-e mounted tothe sheathing 301. The foam layer 304 on each panel interlocks with thefoam layer on adjacent panels such that the fiber cement layers 302 arealigned in a nested configuration. In the embodiment shown in FIG. 5,water draining channels 312 are formed on the front surface of the foamlayer. In some embodiments, the drainage channels 312 can be formed onthe back surface of the foam layer 304, within the interior foam layer,or a combination of the front, back surface and/or interior of the foamlayer. In other embodiments, the drainage channels may be formed on theback face of the fiber cement layer 302. In yet other embodiments, thedrainage channels may be formed in both the foam layer and the fibercement layers. In some implementations, a layer of weather resistantbarrier material 313, such as those marketed under the HardieWrap®brand, can be positioned between the sheathing 301 and the foam layer304 of the fiber cement and foam insulation panel 300 a-300 e.

FIG. 6A illustrates an embodiment of a fiber cement and foam insulationtrim corner 400 with an integrated fastening tab 416. The trim corner400 with the fastening tab 416 is for use around an outside corner of abuilding structure. FIG. 6B illustrates an embodiment of a foaminsulation panel with an integrated fastening tab for use around aninside corner of a building structure. The fastening tabs 416 areconfigured for mounting the fiber cement and foam insulation trim cornerto the building frame or other support structure without having toattach a fastener through the front face of the fiber cement layer 402.As such, the fastening tabs 416 can be used so that the fasteners areconcealed from view upon installation of the panels. The panels 400 mayalso be useful in installations where the wall does not include asheathing to attach the panels. As shown in the illustrated embodimentsin FIGS. 6A-6B, in some embodiments, the fastening tabs 416 can have oneor more overhanging portions 417 extending outwardly from an edge of thefoam layer to fasten to a support structure of a building (e.g.,extending from the lateral edges of the foam layer). In one preferredembodiment, the overhanging portions 417 can be between 3-10 inches(7.62 cm-25.4 cm) in length, more preferably approximately 3 inches(7.62 cm) in length.

As shown in FIG. 6A and FIG. 6C, in some embodiments, the fastening tabs416 can be arranged to be disposed between the fiber cement layer 402and the foam layer 404. In some embodiments, the fastening tab 416 isgenerally formed of a strip of metal shaped to follow the contours ofthe exterior or interior surface of the foam layer 404.

With reference to FIGS. 6A-6B, and FIGS. 6D-6F in some embodiments, thefastening tabs 416 can have a one or more recesses or flat tangs orflanges 419 creating a notched or angled profile. The recesses 419 canallow the overhanging portions 417 to be flush with a surface of thefoam and/or flush with mating components of the building to fasten to asupport structure of the building. Preferably, the recesses 419 arebetween 0.25″ and 1″ in length. The fastening tabs can be installed in amanner such that at least a portion of each fastening tab is concealedfrom view when the wall panel 400 is installed on the building. Thefastening tabs 416 can include angled or filleted corners 478 with radiibetween 1/32″ and 1/16″.

FIGS. 6D-6F illustrate embodiments of fastening tab 416 profiles.

FIG. 6D illustrates an embodiment of a fastening tab 416 profile for usein a fiber cement and foam insulation board installed around an insidecorner. In one implementation, portions 421 a, 421 b of the fasteningtabs 416 adjacent the foam layer can be between 3″ to 11.5″ (7.62 cm to29.21 cm) (421 a) and/or between 4″ to 11.5″ (10.16 cm to 29.21 cm) (421b), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″(0.625 cm) and 1″ (2.54 cm), and the edges 478 can have radii between1/32 (0.079 cm) and 1/16 (0.159 cm), as depicted in FIG. 6D. Such anembodiment can be used for inside corner installations.

FIG. 6E illustrates an embodiment of a fastening tab 416 profile for usein a fiber cement and foam insulation board installed around an outsidecorner. In one implementation, portions 421 a, 421 b of the fasteningtabs 416 adjacent the foam layer can be between 1.5″ to 10.5″ (3.81 to26.67 cm) (421 a) and/or between 2″ to 11″ (5.08 cm to 27.94 cm) (421b), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″(0.625 cm) and 1″ (2.54 cm), and the edges 478 can have radii between1/32 (0.079 cm) and 1/16 (0.159 cm), as depicted in FIG. 6E. Such anembodiment can be used for inside corner installations.

FIG. 6F illustrates another embodiment of a fastening tab 416 profilefor use in an integrated fiber cement and foam insulation panel. In oneimplementation, portions 421 of the fastening tabs 416 adjacent the foamlayer can be between 3″ to 10″ (7.62 cm to 25.4 cm), the overhangingportions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.625 cm) and 1″(2.54 cm), and the edges 478 can have radii between 1/32 (0.079 cm) and1/16 (0.159 cm) as depicted in FIG. 6F. Such an embodiment can be usedfor non-corner installations. It should be appreciated that in otherembodiments, the length of the portion 421 of the fastening tabs 416adjacent the foam layer can be sized to any dimensions necessary tomatch the foam layer length. In one embodiment, the overall thickness ofthe fastening tab 416 is between 16 to 20 gauge, preferably 18 gauge.

FIGS. 6G-6I illustrate embodiments of foam profiles for use withfastening tabs in fiber cement and foam insulation panels.

FIG. 6G illustrates an embodiment of a foam profile for use in an insidecorner section of an integrated fiber cement and foam insulation panelwith integrated fastening tabs. In such an embodiment, the foam layer404 can have an “L” shape configuration and can have a side length 479between 3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 480 between3.5″ to 13″ (8.89 cm to 33.02 cm), with thicknesses 481, 482 between0.25″ to 1.5″ (0.625 cm to 3.81 cm).

FIG. 6H illustrates an embodiment of a foam profile for use in anoutside corner section of a fiber cement and foam insulation panel withintegrated fastening tabs. In such an embodiment, the foam layer 404 canhave an “L” shape configuration and can have a side length 483 between3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 484 between 1.5″ to10.5″ (3.81 cm to 26.67 cm) with thicknesses 485, 486 between 0.25″ to1.5″ (0.625 cm to 3.81 cm).

FIG. 6I illustrates an embodiment of a foam profile for use in a fibercement and foam insulation panel with integrated fastening tabs. In suchan embodiment, the foam layer 404 can have a length 488 between 1.5″ to12″ (3.81 cm to 30.48 cm) with a thickness 487 between 0.25″ to 1.5″(0.625 cm to 3.81 cm).

In some embodiments, the fastening tabs 416 can be attached to the panel400 using one or more connecting elements. The connecting elements caninclude nails, staples, pins, rivets, screws, anchors, clasps, bolts,bucklers, clips, snaps, and other types of fasteners as in known tothose of skill in the art. In yet further embodiments, the foam layercan include one or more recess features (not illustrated) in which thetabs are placed such that the tabs do not extend beyond the back wall ofthe foam layer. In some embodiments, the recess feature in the foamlayer may be formed using the same techniques as for forming drainagechannels and/or interlocking features in a separate step. In addition,the recess features may be formed out of a mold specifically designed toyield a foam layer having drainage channels, interlocking features, andrecess features. In further embodiments, the fastening tabs 416 canattach the panel 400 to the support structure using at least oneconnecting element described above.

FIG. 7 illustrates yet another embodiment of the present disclosureshowing a prefabricated panel 600 including a fiber cement layer 602, abacking 622 and a foam layer 604 disposed therebetween connecting thebacking 622 to the fiber cement layer 602. In some embodiments, thebacking 622 preferably made out of OSB and can be laminated to the foamlayer 604. It will be appreciated that the foam layer 604 and/or thefiber cement layer 602 can incorporate various interlocking features tofacilitate alignment and sealing of the adjacent layers and drainagechannels to facilitate water management.

FIG. 8 illustrates yet another embodiment of the present disclosureshowing an integrated fiber cement and foam insulation panel 700incorporating a discontinuous layer 724 in the foam layer 704 a, 704 b.The discontinuous layer 724 can provide enhanced acoustic dampeningproperties, reducing unwanted outside noise and vibrations from enteringthe building and also reducing interior noises from leaving thebuilding. Such an embodiment can act to give further privacy foroccupants inside of the building. In some implementations, thediscontinuous layer 724 can be made of a viscoelastic material.Preferably, the discontinuous layer 724 is attached to framing membersof the wall to dampen vibrations from the exterior of the building frombeing transmitted to the interior of the building.

FIG. 9 illustrates a further embodiment of the present disclosureshowing a prefabricated fiber cement and foam insulation panel 800designed for high shear applications. The panel 800 includes a fibercement layer 802, a foam layer 804, and a mesh 826 disposed therebetweenfor reinforcement. In some embodiments, the panel 800 can providesufficient shear strength to eliminate or substantially reduce the needfor structural sheathing, such as OSB. In other embodiments, the foamlayers may include facing materials such as meshes or non woven sheetsto enhance the shear strength of the fiber cement and foam insulationpanel 800. In yet further embodiments, the panel 800 may alsoincorporate mesh or reinforcing fibers within the body of the foamlayer. The panel may include vapor permeable facing materials adjacentthe foam layer, including foils or films to reflect heat or heat lossdue to air permeability.

FIGS. 10A-10C illustrate further embodiments of the present disclosureshowing two fiber cement and foam insulation panels 900 a, 900 b joinedtogether with a butt joint 926. The panels include fiber cement layers902 a, 902 b and profiled foam layers 904 a, 904 b. In this embodiment,the profiled foam layers 904 a, 904 b extend only a partial length ofeach respective fiber cement layer 902 a, 902 b, thus leaving a space onboth ends of each fiber cement layer configured to receive an insert928. The insert 928 can be placed at the joint 926 to mitigate waterpenetration into the wall and allow condensation to drip over the faceof the plank below the lap siding. The insert 928 can include a foamlayer 932 laminated with a piece of house wrap or flashing 930. Theflashing 930 may be used as a water resistive barrier. The flashing 930can be constructed to be longer than the foam layer 932 such that whenjoined together to form the insert 928, the flashing includes anoverhang 931 which extends beyond a length of the foam layer 93 (bestdepicted in FIG. 10B). In one preferred embodiment, the foam layer 932of the insert 928 can have a nominal width of 6 inches (15.24 cm) andthe flashing 930 can have an overhang 931 of approximately 1.16 inches(2.95 cm). In one embodiment, the insert 928 can include a foam layer932 having a profile that matches the profile of the mating foam layers904 a, 904 b of the adjacent panels 900 a, 900 b.

FIGS. 11A and 11B are schematic illustrations of certain connectionmechanism that can be used to join adjacent integrated fiber cement andfoam panels 1100 a, 1100 b at a butt joint. In one embodiment, a recess1101 a, 1101 b is formed along the lateral edges of each panel 1100 a,1100 b. Each recess is configured to receive a portion of an insert 1102a, 1102 b designed to join the two panels. The insert 1102 a, 1102 b canassume a variety of different shapes and configurations. In oneembodiment, the insert 1102 b is an elongate planar member that can bemade out of foam, fiber cement, or other material. The insert 1102 b canbe inserted between the two panels and slidingly engage with therecesses formed on the edge of each panel. In some embodiments, theinsert 1102 a is keyed to mate with corresponding patterns in the recess1101 a, 1101 b so as to interlock and further secure the two panels.

FIG. 12 depicts a flow diagram of installation 1000 of fiber cement andfoam insulation panels on a wall according to one embodiment. The methodincludes cutting and trimming 1002 starter strips. As described above,starter strips can be used to ensure a consistent plank angle for theintegrated panels. The method next includes installing 1004 the starterstrips at the base of the wall. Starter strips may be fastened to thewall using one or more fasteners described above (e.g. siding nails from6 d to 16 d). The starter strips may be fastened to a sheathing (whenpresent) or directly to the studs of the building. The method furtherincludes cutting and trimming 1006 the integrated fiber cement and foaminsulation panels. The method next includes installing 1008 the fibercement and foam insulation panels to the wall. In some embodiments, asdescribed above, the panels can include interlocking features fornesting or crotchedly connecting the panels. In some embodiments, asdescribed with reference to FIGS. 6A-61, panels incorporating fasteningtabs can be used. As described above, fastening tabs may be useful ininstallations where the wall does not include a sheathing to attach thepanels to conceal the fasteners. The method optionally includesinstalling 1010 inserts at the butt joints between adjacent panels, asdescribed with reference to FIGS. 10A-10C and 11A-11B. As describedabove, the inserts can include a flashing to act as a water resistivebarrier.

FIG. 13 illustrates yet another embodiment of an integrated fiber cementand foam insulation panel 1300. The panel 1300 generally includes twofiber cement layers 1302 a, 1302 b and a profiled foam layer 1304disposed therebetween. The fiber cement layers 1302 a, 1302 b can beattached to opposing faces of the foam layer 1304 via a suitableadhesive. As shown in FIG. 13, the thickness of the foam layer 1304 canbe substantially greater than the thickness of the fiber cement layers1302. In some embodiments, the foam layer 1304 includes profiled edgesconfigured to mate and interlock with corresponding edges on adjacentpanels, thereby forming a continuous surface. The panel 1300 ispreferably pre-fabricated so that it can be used readily at theconstruction site.

The advantages of the prefabricated integrated fiber cement and foamcomposite insulation panel include a higher R-value fiber cementbuilding material that is easily installed, provides a building envelopethat resists penetration from the elements yet can breath and drainwater away from the interior, and a faster installation time when abuilder decides to use foam insulation on the structure.

To avoid over-compression and distortion when attaching the integratedfiber cement and foam panels to a wall, the foam preferably has aminimum compressive strength of about 15 psi as determined by ASTM D6817. In some embodiments, to ensure that the integrated fiber cementand foam system has a minimum wind load resistance of 3.0 kPa ultimateload when tested using an ASTM E 330 vacuum testing apparatus, theminimum compressive strength of the foam is preferably about 15 psi asdetermined by ASTM 6817. In one embodiment, an integrated fiber cementand foam insulation cladding panel, formed in accordance with thedesigns disclosed herein, has a wind load of greater than 83 psf,preferably greater than or equal to 94 psf.

The foregoing description of the preferred embodiments of the presentdisclosure has shown, described and pointed out the fundamental novelfeatures of the inventions. The various devices, methods, procedures,and techniques described above provide a number of ways to carry out thedescribed embodiments and arrangements. Of course, it is to beunderstood that not necessarily all features, objectives or advantagesdescribed are required and/or achieved in accordance with any particularembodiment described herein. Also, although the invention has beendisclosed in the context of certain embodiments, arrangements andexamples, it will be understood by those skilled in the art that theinvention extends beyond the specifically disclosed embodiments to otheralternative embodiments, combinations, sub-combinations and/or uses andobvious modifications and equivalents thereof. Accordingly, theinvention is not intended to be limited by the specific disclosures ofthe embodiments herein.

What is claimed is:
 1. An exterior cladding system for buildingstructures, comprising: a first panel and a second panel, wherein eachpanel comprises a fiber cement layer and a foam layer, wherein the fibercement layer of each panel is pre-attached to the respective foam layerby an adhesive selected to accommodate the stresses generated by cyclicdifferential expansion between the fiber cement layer and the foamlayer; and wherein the foam layer of the first panel comprises anelongate mating channel defined by two opposing sidewalls formed along alongitudinal edge of the foam layer of the first panel, wherein the foamlayer of the second panel comprises an elongate protrusion formed alonga longitudinal edge of the foam layer of the second panel, saidprotrusion on the foam layer of the second panel is configured to bereceived into the mating channel on the foam layer of the first panel ina manner such that the sidewalls formed on the foam layer of the firstpanel enclose the protrusion formed on the foam layer of the secondpanel in a manner such that the foam layers of the first and secondpanels interlock.
 2. The system of claim 1, wherein a plurality ofdrainage channels are formed in the foam layers of at least one of thepanels.
 3. The system of claim 2, wherein the drainage channels areformed on at least one of the surfaces of the foam layer.
 4. The systemof claim 1, wherein a plurality of drainage channels are formed in thefiber cement layer of at least one of the panels.
 5. The system of claim2, wherein the drainage channels are configured to function as logos. 6.The system of claim 2, wherein the drainage channels comprise a chevronpattern design.
 7. The system of claim 1, wherein the fiber cement layeris a siding.
 8. The system of claim 1, wherein at least one of thepanels further comprises an oriented strand board (OSB), said OSB isattached to the foam layer on the opposing side of the fiber cementlayer of the panel.
 9. The system of claim 1, wherein a reinforcementmesh layer embedded in at least one of the foam layers.
 10. The panel ofclaim 9, wherein the one or more fastening tabs are disposed between thefoam layer and the fiber cement layer.
 11. The panel of claim 9, whereinthe one or more fastening tabs are attached to the panel in a mannersuch that a portion of each tab extends outwardly from the lateral edgesof the foam layer.
 12. A method of installing integrated fiber cementand foam insulation panels on a building structure having a framing,said method comprising: installing one or more starter strips at thebase of a wall of the building to form a plank angle; installing thefiber cement and foam insulation panels sequentially up the wall; andcrotchedly vertically nesting the fiber cement and foam insulationpanels.
 13. The method of claim 12, the method further comprising thesteps of installing an insert behind a butt joint intersection betweenadjacent fiber cement and foam insulation panels; wherein the insertcomprises a foam layer with the same profile as a foam layer in thefiber cement and foam insulation panels and a flashing layer.
 14. Themethod of claim 13, wherein the fiber cement and foam insulation panelcomprises one or more fastening tabs, the method further comprising thesteps of: installing the panels to the framing by attaching the one ormore fastening tabs to the framing, wherein the fastening tabs areattached to the fiber cement and foam insulation panels in such a mannerthat at least a portion of each fastening tab is concealed from viewwhen the panels are installed on the building structure.